Extended via semiconductor structure, device and method

ABSTRACT

A device includes a substrate, a first conductive layer on the substrate, a first conductive via, and further conductive layers and conductive vias between the first conductive via and the substrate. The first conductive via is between the substrate and the first conductive layer, and is electrically connected to the first conductive layer. The first conductive via extends through at least two dielectric layers, and has thickness greater than about 8 kilo-Angstroms. An inductor having high quality factor is formed in the first conductive layer and also includes the first conductive via.

BACKGROUND

Inductors are building blocks for integrated circuits. An inductorfabricated in an integrated circuit process generally includes aconductive spiral coil, input and output traces and pads, all of whichare formed at least partially in the uppermost metal layer of anintegrated circuit. One performance metric of inductors is a quality, or“Q,” factor. In radio frequency electronics, the Q factor can be seen asa measure of signal selectivity, the ability to attenuate unwantedsignals, particularly those adjacent to a desired frequency band, whilesimultaneously retaining signals in the desired frequency band.Increasing the Q factor improves the signal selectivity, and is animportant objective in the design of inductors fabricated in integratedcircuit processes.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 is a top view of an inductor in accordance with some embodiments.

FIG. 2 is a perspective view of adjacent bends of the inductor of FIG. 1in accordance with some embodiments.

FIG. 3 is a circuit diagram of the inductor of FIG. 1 in accordance withsome embodiments.

FIG. 4 is a cross-sectional diagram of a structure of the inductor ofFIG. 1 in accordance with some embodiments.

FIGS. 5 a-5 n are cross-sectional diagrams of a method of fabricatingthe structure of FIG. 4 in accordance with some embodiments.

FIG. 6 is a flow chart of the method of fabricating the conductiveportion in accordance with some embodiments.

FIG. 7 is a circuit block diagram of a passive radio frequency device inaccordance with some embodiments.

FIG. 8 is a circuit block diagram of an active radio frequency device inaccordance with some embodiments.

FIG. 9 is a circuit block diagram of a voltage controlled oscillatordevice in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

The term “top metal layer” may be used herein to refer to the metallayer of an integrated circuit chip (or simply “chip”) most distal asubstrate of the chip, and/or the metal layer of the chip above which nofurther metal layers are formed. The term “bottom metal layer” may beused herein to refer to the metal layer of the chip most proximal thesubstrate, and/or the metal layer of the chip having no metal layerbetween itself and the substrate. The term “intermediate metal layer”may be used herein to refer to any metal layer between the top metallayer and the bottom metal layer.

The term “upper conductive via” may be used herein to refer to anyconductive via in direct contact with the top metal layer. The term“intermediate conductive via” may be used herein to refer to anyconductive via not having a direct contact with the top metal layer.

On-chip inductor quality factor is closely correlated with variousdesirable performance metrics in integrated circuit design, includingbut not limited to radio frequency sideband rejection and voltagecontrolled oscillator phase noise reduction. Substrate loss andself-resonance are two environmental challenges that obstruct designers'ability to produce on-chip inductors exhibiting high quality factor.Increase in oxide capacitance C_(ox), the capacitance between theinductor and the substrate over which it is formed, effectively reducesboth the substrate loss and the self-resonance. Oxide capacitance C_(ox)is inversely proportional to oxide thickness t_(ox), suggesting thatquality factor can be increased by increasing oxide thickness t_(ox) ofthe inductor.

Various embodiments of integrated circuit structures and process flowsdirected toward increasing oxide thickness t_(ox) with a view toreducing substrate loss factor and self-resonance factor to increasequality factor of on-chip inductors are described below. In someembodiments, oxide thickness t_(ox) is increased by extending an upperconductive via through at least two dielectric layers. In someembodiments, the oxide thickness is further increased by extending theupper conductive via through at least one etch stop layer positionedbetween the at least two dielectric layers. Q factor for a 0.5nano-Henry on-chip inductor is greater than about 22 when using thestructures and processes described herein.

FIG. 1 is a top view of inductor circuit 10 in accordance with someembodiments. Inductor circuit 10 is an on-chip inductor in a chip.Inductor circuit 10 is fabricated in an integrated circuit fabricationprocess. Inductor circuit 10 is on a substrate of the chip. In someembodiments, the substrate is a semiconductor substrate, such as a bulksemiconductor, a semiconductor-on-insulator (SOI) substrate, or thelike, which may be doped with a p-type or an n-type dopant or undoped.In some embodiments, the substrate is a wafer, such as a silicon wafer.An SOI substrate generally includes a layer of semiconductor materialformed on an insulator layer. In some embodiments, the insulator layeris a buried oxide (BOX) layer, a silicon oxide layer, or the like. Theinsulator layer is provided on a substrate, typically a silicon or glasssubstrate. In some embodiments, a multi-layered or gradient substrate isused. In some embodiments, the semiconductor material of the substrateincludes silicon and/or germanium. In some embodiments, thesemiconductor material is a compound semiconductor including siliconcarbide, gallium arsenic, gallium phosphide, indium phosphide, indiumarsenide, and/or indium antimonide. In some embodiments, the substrateis an alloy semiconductor including SiGe, GaAsP, AlInAs, AlGaAs, GaInAs,GaInP, and/or GaInAsP. Combinations of the above may be utilized as thesubstrate in some embodiments.

The substrate will generally include integrated circuit devices (notshown). In some embodiments, the integrated circuit devices includetransistors, diodes, capacitors, resistors, the like, or combinationsthereof formed in and/or on the substrate. The integrated circuitdevices may be formed using any suitable methods.

The inductor circuit 10 includes an inductor 100 having any suitableshape or architecture. In some embodiments, the inductor 100 may be asymmetrical or generally symmetrical spiral inductor 100 having anoctagonal-shaped coil (or simply “coil”) 130. First trace 141 and firstpad 142, and second trace 143 and second pad 144 provide input andoutput electrical signal connection to coil 130. In some embodiments,first guard ring segment 110 and second guard ring segment 120 partiallysurround spiral inductor 100, as shown in FIG. 1 . In some embodiments,the first guard ring segment 110 and/or second guard ring segment 120may be omitted. In some embodiments, coil 130 is formed at leastpartially in the top metal layer of the chip. Forming coil 130 in thetop metal layer can reduce parasitic capacitances, which are generallyinversely proportional to the distance, or “oxide thickness” (t_(ox)),between the coil and the substrate over which the coil is formed.

Throughout the description, reference to inductor circuit 10 is notlimited to the symmetrical spiral inductor architecture shown in FIG. 1. Other inductor architectures including at least asymmetrical spiralinductors may be utilized as the inductor 100 in the inductor circuit 10in various embodiments, and the techniques described for improvinginductor Q factor are applicable to the other inductor architectureswithout significant modification envisioned. Symmetrical spiralinductors generally trade off lower self-resonant frequency againsthigher inductance, higher Q factor and lower series resistance.

Other inductor shapes including at least hexagonal, square or circularmay be utilized as the inductor 100 in the inductor circuit 10 invarious embodiments, and the techniques described for improving inductorQ factor are applicable to the other inductor shapes without significantmodification envisioned. Whereas circle-shaped inductors exhibitfavorable Q factor, few or no semiconductor fabrication processessupport shapes employing curved sides. Square-shaped inductors aregenerally more compact, easily manufactured, and exhibit higherinductance for a given area, but suffer lower Q factor. Octagonal-shapedand hexagonal-shaped inductors strike a desirable balance betweenmanufacturability, Q factor and inductance. Again, any of the shapeswill benefit from application of the Q factor enhancing techniquesdescribed herein. Other examples of a substantially closed geometricpattern would include a box-within-a-box pattern (square or rectangular)or other polygon spiral pattern, an irregularly shaped spiral pattern,nested parallelogram or polygon patterns, and the like.

In some embodiments, inductor circuit 10 has a Q factor of greater thanabout 21, greater than about 22, greater than about 23, or greater thanabout 24. In some embodiments, inductor circuit 10 has inductance ofless than about 1 nano-Henry, less than about 0.5 nano-Henries, or lessthan about 0.1 nano-Henries. Lower inductance can be desirable toachieve higher operating frequency.

Spiral inductor 100 of inductor circuit 10 includes coil 130, firsttrace 141, first pad 142, second trace 143 and second pad 144.

First coil segment 131 of coil 130 is a first outer ring segment of coil130. In some embodiments, first coil segment 131 includes at least 3bends, at least 4 bends or at least 5 bends. A “bend” as describedherein can refer to a change in direction of a segment of the coil 130.A circular inductor would thereby have infinite bends, and a polygonalinductor would have some finite number of bends. In some embodiments,first coil segment 131 is monolithically formed with first trace 141. Insome embodiments, first coil segment 131 is electrically connected tofirst trace 141 by way of a conductive via.

Second coil segment 132 is an inner ring segment of coil 130. In someembodiments, second coil segment 132 includes at least 4 bends, at least6 bends or at least 8 bends. In some embodiments, second coil segment132 is monolithically formed with first coil segment 131 and/or firsttrace 141, or electrically connected thereto by way of a conductive via.

Third coil segment 133 is a first bridge segment electrically connectedto first coil segment 131 and second coil segment 132. In someembodiments, third coil segment 133 is monolithically formed with firstcoil segment 131 and second coil segment 132, or electrically connectedthereto by way of a conductive via.

Fifth coil segment 135 is a second outer ring segment of coil 130. Insome embodiments, fifth coil segment 135 includes at least 3 bends, atleast 4 bends, or at least 5 bends. In some embodiments, fifth coilsegment 135 is monolithically formed with second trace 143. In someembodiments, fifth coil segment 135 is electrically connected to secondtrace 143 by way of a conductive via.

Fourth coil segment 134 is a second bridge segment electricallyconnected to fifth coil segment 135 and second coil segment 132. Fourthcoil segment 134 crosses under third coil segment 133, and iselectrically isolated from third coil segment 133. In some embodiments,fourth coil segment 134 is formed in at least one intermediate metallayer.

Sixth coil segment 136 is a first intermetal connection region partiallyoverlapping second coil segment 132 and fourth coil segment 134. In someembodiments, sixth coil segment 136 includes one or more conductive viasand one or more metal contacts extending from second coil segment 132 tofourth coil segment 134. Sixth coil segment 136 establishes anelectrical connection between second coil segment 132 and fourth coilsegment 134.

Seventh coil segment 137 is a second intermetal connection regionpartially overlapping fifth coil segment 135 and fourth coil segment134. In some embodiments, seventh coil segment 137 includes one or moreconductive vias and one or more metal contacts extending from fifth coilsegment 135 to fourth coil segment 134. Seventh coil segment 137establishes an electrical connection between fifth coil segment 135 andfourth coil segment 134.

In some embodiments, first pad 142, first trace 141, first coil segment131, third coil segment 133, second coil segment 132, fifth coil segment135, second trace 143 and second pad 144 (“the segments”) are formed inthe top metal layer of the chip. In some embodiments, the segments arefurther formed in at least one intermediate metal layer and/or thebottom metal layer, the included metal layers in the segments beinginterconnected by conductive vias. Forming the segments in more than onemetal layer reduces series resistance of spiral inductor 100 byeffectively increasing cross-sectional area of the current path throughthe spiral inductor 100 (resistance is inversely proportional tocross-sectional area), which is desirable in some circuit applications.

In some embodiments, any of first pad 142, first trace 141, first coilsegment 131, third coil segment 133, second coil segment 132, fifth coilsegment 135, second trace 143 and second pad 144 includes at least oneupper conductive via extending from the top metal layer through at leasttwo dielectric layers. Each upper conductive via in spiral inductor 100is a single, continuous structure. In some embodiments, formation ofupper conductive vias is accomplished using no more than one electrolesscopper plating step.

First guard ring segment 110 and second guard ring segment 120 form aguard ring around coil 130. The guard ring attenuates radio frequencynoise emitted by coil 130. The attenuation protects nearby circuitswhich may be sensitive to such electromagnetic interference generated bycoil 130.

FIG. 2 is a perspective view of adjacent bends of the inductor of FIG. 1in accordance with some embodiments. FIG. 3 is a circuit diagram of theinductor of FIG. 1 in accordance with some embodiments. Two metal layersare shown in FIG. 2 for ease of illustration. Other embodiments mayinclude more than two metal layers.

Inductor section 20 includes substrate 240 and dielectric layer 230 on afirst side of substrate 240. Portions of first coil segment 131 andsecond coil segment 132 are shown in FIG. 2 , as well as front and sidecutaways. Equivalent circuit components including inductance 330,resistance 331, capacitance 332, capacitance 340, resistance 350, andcapacitance 360 are also shown overlaid on the perspective view in FIG.2 for ease of description.

Equivalent circuit 30 shown in FIG. 3 is a pi-type lumped physical modelfor approximating electrical behavior of on-chip inductors, such asspiral inductor 100.

Inductance 330 models series inductance of spiral inductor 100. A firstterminal of inductance 330 is electrically connected to a first terminalof capacitance 332, a first terminal of capacitance 340, and firstinterface terminal 310. A second terminal of inductance 330 iselectrically connected to a first terminal of resistance 331.

Resistance 331 models series resistance of spiral inductor 100. A firstterminal of resistance 331 is electrically connected to the secondterminal of inductance 330. A second terminal of resistance 331 iselectrically connected to a second terminal of capacitance 332, a firstterminal of capacitance 341, and second interface terminal 320.

Capacitance 332 represents series capacitance of spiral inductor 100.Capacitance 332 generally models capacitive coupling in spiral inductor100. One type of capacitive coupling is shown in FIG. 2 between firstcoil segment 131 and second coil segment 132. Overall capacitivecoupling represented by capacitance 332 is generally thought to bedominated by the crossover of third coil segment 133 and fourth coilsegment 134 of coil 130 shown in FIG. 1 . A first terminal ofcapacitance 332 is electrically connected to first interface terminal310, the first terminal of inductance 330, and the first terminal ofcapacitance 340. A second terminal of capacitance 332 is electricallyconnected to the second terminal of resistance 331, the first terminalof capacitance 341, and second interface terminal 320.

Capacitance 340 and capacitance 341 model oxide capacitance of spiralinductor 100 distributed at first interface terminal 310 and secondinterface terminal 320, respectively. The oxide capacitance of spiralinductor 100 is generally modeled as equally distributed:C_(ox1)=C_(ox2)=C_(ox). Capacitance 340 and capacitance 341 representcapacitance of dielectric layer 230 between first coil segment 131 andsubstrate 240, and second coil segment 132 and substrate 240,respectively.

Resistance 350 and resistance 351 model resistance of substrate 240 fromdielectric layer 230 to biasing terminal 370, corresponding toresistance from the second terminal of capacitance 340 to biasingterminal 370 and from the second terminal of capacitance 341 to biasingterminal 370, respectively. Capacitance 360 and capacitance 361 modelcapacitance of substrate 240 from dielectric layer 230 to biasingterminal 370, corresponding to capacitance from the second terminal ofcapacitance 340 to biasing terminal 370 and from the second terminal ofcapacitance 341 to biasing terminal 370, respectively. Resistance 350and resistance 351 are generally modeled as equally distributed:R_(sub1)=R_(sub2)=R_(sub). Capacitance 360 and capacitance 361 aregenerally modeled as equally distributed: C_(sub1)=C_(sub2)=C_(sub).

Q factor of spiral inductor 100 is approximated by equivalent circuit 30as:

$\begin{matrix}{Q = {\frac{\omega L_{s}}{R_{s}} \times \frac{R_{p}}{R_{p} + {\left\lbrack \left( \frac{\omega L_{s}}{R_{s}} \right)^{2} \right\rbrack R_{s}}} \times \left\lbrack {1 - \frac{R_{s}^{2}\left( {C_{i} + C_{p}} \right)}{L_{s}} - {\omega^{2}{L_{s}\left( {C_{i} + C_{p}} \right)}}} \right\rbrack}} & (1)\end{matrix}$ $\begin{matrix}{R_{p} = {\frac{1}{\omega^{2}C_{ox}^{2}R_{sub}} + \frac{{R_{sub}\left( {C_{ox} + C_{sub}} \right)}^{2}}{C_{ox}^{2}}}} & (2)\end{matrix}$ $\begin{matrix}{C_{p} = {C_{ox}\frac{1 + {{\omega^{2}\left( {C_{- {ox}} + C_{sub}} \right)}C_{sub}R_{sub}^{2}}}{1 + {{\omega^{2}\left( {C_{ox} + C_{sub}} \right)}^{2}R_{sub}^{2}}}}} & (3)\end{matrix}$

The middle term of (1) denotes what is generally known as the substrateloss factor, which is a number less than unity that approaches one asparasitic R_(p) dominates the second term in the denominator. Parasiticresistance R_(p) is expanded as (2). From (2), decreasing C_(ox)increases R_(p). Increased R_(p) raises the substrate loss factor closerto one, which improves Q factor.

The third term of (1) denotes what is generally known as theself-resonance factor, which is also a loss factor less than unity.Parasitic capacitance C_(p) is expanded as (3). The self-resonancefactor is increased if C_(p) is decreased. From (3), C_(p) is decreasedwhen C_(ox) is decreased.

C_(ox) is generally obtained by:

$\begin{matrix}{C_{ox} = {\frac{1}{2}{lw}\frac{\varepsilon_{ox}}{t_{ox}}}} & (4)\end{matrix}$

From (4), C_(ox) is directly proportional to inductor area lw and oxidepermittivity ε_(ox), and inversely proportional to oxide thicknesst_(ox). Increased oxide thickness t_(ox) decreases C_(ox), which reducesthe substrate loss factor and the self-resonance factor, therebyincreasing the Q factor. “Oxide thickness” generally refers to thicknessof oxide, or other suitable dielectric, between spiral inductor 100 andthe substrate. Oxide thickness may be measured as distance between asurface of spiral inductor 100 proximal the substrate and the substrateitself. One measure of oxide thickness in accordance with variousembodiments is shown in FIG. 4 , labeled “t_(ox).”

Use of an extended (e.g., taller or deeper) upper conductive viaeffectively increases oxide thickness t_(ox) by increasing distancebetween the inductor 100 and the substrate. To enhance inductor qualityfactor and overall device performance, in some embodiments, oxidethickness t_(ox) is increased by extending an upper conductive viathrough at least two dielectric layers. In some embodiments, the oxidethickness is further increased by extending the upper conductive viathrough at least one etch stop layer positioned between the at least twodielectric layers.

Structure 210 and structure 220, each of which includes such an upperconductive via, are highlighted in FIG. 2 . Positioning of via 213, anupper conductive via, among first metal line 211 and second metal line212 of first coil segment 131 is shown in FIG. 2 . FIG. 5 n showsstructure 210 in accordance with at least one embodiment. In someembodiments, first coil segment 131 includes at least ten, at least onehundred or more structures 210 distributed throughout first coil segment131. Structure 220 is included in second coil segment 132. Structure 220is highlighted to illustrate at a conceptual level positioning of via223 among third metal line 221 and fourth metal line 222 of second coilsegment 132. In some embodiments, second coil segment 132 includes atleast ten, at least one hundred or more structures 220 distributedthroughout second coil segment 132. In some embodiments, structuressimilar to structure 210 or structure 220 are included in first pad 142,first trace 141, third coil segment 133, fifth coil segment 135, secondtrace 143 and/or second pad 144.

In some embodiments, an array of structures 210 or structures 220 isdistributed throughout spiral inductor 100, each structure 210 orstructure 220 having width of about 0.1 micrometers to about 10micrometers, length of about 0.1 micrometers to about 10 micrometers,and the array having pitch/spacing of about 0.1 micrometers to about 10micrometers. Other embodiments may utilize greater or lesser length,width and/or array pitch/spacing. In some embodiments, structures 210 orstructures 220 are distributed non-uniformly in one or more regions ofspiral inductor 100 or inductor circuit 10.

Via 213 is an upper conductive via. Via 213 is in direct contact withfirst metal line 211 and in direct contact with second metal line 212.In some embodiments, via 213 is or comprises a metal, such as tungsten,copper, aluminum, gold, silver, alloys thereof, the like, or acombination thereof, and may be deposited by chemical vapor deposition(CVD), atomic layer deposition (ALD), physical vapor deposition (PVD),electroplating, electroless plating, or other suitable method.

Via 223 is an upper conductive via. Via 223 is in direct contact withthird metal line 221 and in direct contact with fourth metal line 222.In some embodiments, via 223 is or comprises a metal, such as tungsten,copper, aluminum, gold, silver, alloys thereof, the like, or acombination thereof, and may be deposited by chemical vapor deposition(CVD), atomic layer deposition (ALD), physical vapor deposition (PVD),electroplating, electroless plating, or other suitable method.

Various embodiments of integrated circuit structures and process flowsdirected toward increasing oxide thickness with a view to reducingsubstrate loss factor and self-resonance factor to increase qualityfactor of an on-chip inductor are described below. In some embodiments,oxide thickness is increased by extending an upper conductive viathrough at least two dielectric layers to increase distance between theinductor 100 and the substrate. In some embodiments, the oxide thicknessis further increased by extending the upper conductive via through atleast one etch stop layer positioned between the at least two dielectriclayers. Q factor for an on-chip inductor of 0.5 nano-Henries is greaterthan about 22 when using the structures and processes described herein.

FIG. 4 is a diagram of a conductive stack 40 in accordance with someembodiments. Stack 40 is depicted showing metal features 211, 212, 422,432, 442, 452, 462, 472, 482, dielectric layers 400, 410, 415, 420, 425,430, 435, 440, 445, 450, 455, 460, 465, 470, 475, 480, 485, substrate240, and conductive vias 213, 421, 431, 441, 451, 461, 471, 481 from abottom metal layer, through various intermediate metal layers, to a topmetal layer. Seven intermediate metal layers are shown in FIG. 4 . Insome embodiments, fewer or more intermediate metal layers are utilized.

Seventeen dielectric layers are shown in FIG. 4 . For clarity ofillustration, intervening functional layers, including etch stop layers,anti-reflective layers, and the like, are not depicted in FIG. 4 . Insome embodiments, one or more functional layers are included between oneor more of the dielectric layers. In some embodiments, dielectric layer410 comprises at least dielectric layers 511, 512 and functional layers501, 502, 503 shown in FIG. 5 n . In some embodiments, dielectric layers420, 430, 440, 450, 460, 470, 480 each have thickness less thanthickness of dielectric layer 410. In some embodiments, dielectriclayers 420, 430, 440, 450, 460, 470, 480 have thickness less than 7kilo-Angstroms.

Conductive feature 482 is a bottom metal layer contact in dielectriclayer 485. Via 481 is a bottom metal layer via in dielectric layer 480and directly contacting conductive feature 482. Via 481 and dielectriclayer 485 are on substrate 240. In some embodiments, no interveningmetal layer exists between the surface of conductive feature 482 facingsubstrate 240 and substrate 240.

Conductive feature 472 is a first intermediate layer contact indielectric layer 475. Conductive feature 472 is in direct contact withvia 481. Conductive features 462, 452, 442, 432, 422 and second metalline 212 are second, third, fourth, fifth, sixth and seventhintermediate layer conductive features, respectively. In someembodiments, conductive features 432, 442, 452, 462, 472 havesubstantially the same thickness. In some embodiments, conductivefeature 422 has substantially the same thickness as second metal line212. In some embodiments, thickness of conductive features 432, 442,452, 462, 472 is different from thickness of conductive feature 422 andsecond metal line 212. In some embodiments, conductive feature 422 andsecond metal line 212 are thicker than conductive features 432, 442,452, 462, 472. Second metal line 212 and conductive features 422, 432,442, 452, 462, 472, 482 are or comprise at least one conductivematerial. In some embodiments, the at least one conductive material isor comprises a metal, such as tungsten, copper, aluminum, gold, silver,alloys thereof, the like, or a combination thereof, and may be depositedby chemical vapor deposition (CVD), atomic layer deposition (ALD),physical vapor deposition (PVD), electroplating, electroless plating, orother suitable method.

Via 471 is a first intermediate layer via in dielectric layer 470. Via471 is in direct contact with conductive feature 472 and conductivefeature 462. Via 461 is a second intermediate layer via in directcontact with conductive feature 462 and conductive feature 452. Via 451is a third intermediate layer via in direct contact with conductivefeature 452 and conductive feature 442. Via 441 is a fourth intermediatelayer via in direct contact with conductive feature 442 and conductivefeature 432. Via 431 is a fifth intermediate layer via in direct contactwith conductive feature 432 and conductive feature 422. Via 421 is asixth intermediate layer via in direct contact with conductive feature422 and second metal line 212. In some embodiments, vias 421, 431 havesubstantially the same thickness. In some embodiments, vias 441, 451,461, 471, 481 have substantially the same thickness. In someembodiments, thickness of vias 441, 451, 461, 471, 481 is different fromthickness of vias 421, 431. In some embodiments, vias 421, 431 arethicker than vias 441, 451, 461, 471, 481.

Via 213 is an upper conductive via. Thickness of via 213 is labeled “t”in FIG. 4 . Thickness of via 213 is greater than thickness of anyintermediate conductive via between the surface of via 213 facingsubstrate 240 and substrate 240.

In some embodiments, thickness of via 213 is greater than about 8kilo-Angstroms. In some embodiments, thickness of via 213 is in a rangeof about 8 kilo-Angstroms to about 30 kilo-Angstroms. Below 8kilo-Angstroms, via 213 may not be thick enough to provide sufficientpower-handling capability, and may also introduce excessive intermetalcapacitance between first metal line 211 and second metal line 212.Formation of via 213 through a single oxide layer having thickness inexcess of 30 kilo-Angstroms may adversely affect process uniformity whenetching an opening for via 213 through the single oxide layer in whichthe via 213 is formed.

In some embodiments, via 213 is extended through at least two dielectriclayers of dielectric layer 410 to further increase the oxide thicknessby further increasing distance between the inductor 100 and thesubstrate. Use of two dielectric layers separated by an etch stop layerallows for a thicker via 213 while avoiding adverse effects on processuniformity by etching the two dielectric layers in two distinct etchingoperations. In some embodiments, thickness of via 213 extending throughat least two dielectric layers is in a range of about 16 kilo-Angstromsto 60 kilo-Angstroms. In some embodiments, via 213 has thickness ofabout 48 kilo-Angstroms. Via 213 having thickness much greater than 8kilo-Angstroms effectively increases t_(ox), thereby reducing C_(ox) andincreasing quality factor. Further dielectric layers and etch stoplayers may be introduced to further increase thickness of via 213. Via213 having excessive thickness may introduce unwanted stress on thelower metal layers, which may lead to delamination.

FIG. 5 a to FIG. 5 n are diagrams showing intermediate semiconductorstructures illustrating a method of fabricating structure 210 of FIG. 2and FIG. 4 in accordance with some embodiments. FIG. 6 is a flow chartof the method of fabricating the structure 210 in accordance with someembodiments. FIG. 5 a to FIG. 5 j generally relate to formation of via213. FIG. 5 k to FIG. 5 n generally relate to formation of first metalline 211.

In FIG. 5 a , second metal line 212 is provided. In some embodiments,second metal line 212 is a contact or trace in an intermediate metallayer. In some embodiments, formation of second metal line 212 isachieved by at least defining a feature in a lithography process,removing dielectric material to form an opening substantiallycorresponding to the feature, depositing or plating a conductivematerial in and over the opening, and planarizing and/or polishing theconductive material and the dielectric layer. In some embodiments, theat least one conductive material is or comprises a metal, such astungsten, copper, aluminum, gold, silver, alloys thereof, the like, or acombination thereof, and may be deposited by chemical vapor deposition(CVD), atomic layer deposition (ALD), physical vapor deposition (PVD),electroplating, electroless plating, or other suitable method. In someembodiments, a barrier seed layer is formed in the opening prior todepositing or plating the conductive material in the opening.

FIG. 5 b shows an intermediate semiconductor structure after performingoperation 600 of the flowchart 60 shown in FIG. 6 . In FIG. 5 b ,functional layer 501 is formed on second metal line 212. In someembodiments, functional layer 501 is a first functional layer. In someembodiments, functional layer 501 is a first etch stop layer. Forexample, as shown in FIG. 6 , operation 600 may include formingfunctional layer 501 by deposition of a first etch stop layer (ESL1).Generally, an etch stop layer (ESL) provides a mechanism to stop an etchprocess when forming conductive features, such as contacts or vias. AnESL may be formed of a dielectric material having a different etchselectivity from adjacent layers or components. In some embodiments,functional layer 501 comprises or is silicon nitride, silicon carbonnitride, silicon carbon oxide, carbon nitride, silicon carbide, thelike, or a combination thereof deposited by an appropriate depositionprocess. In some embodiments, thickness of functional layer 501 is in arange of about 300 Angstroms to 1000 Angstroms. In some embodiments,functional layer 501 is formed of silicon carbide and has thickness ofabout 750 Angstroms. It may be advantageous to use a thick functionallayer 501 both to avoid forming voids in the functional layer 501 and toincrease thickness of via 213 and oxide thickness t_(ox). An excessivelythick functional layer 501 may increase etching time and volume ofetchant consumed to etch through functional layer 501.

FIG. 5 c shows an intermediate semiconductor structure after performingoperation 601 of FIG. 6 . In FIG. 5 c , functional layer 502 is formedon functional layer 501. In some embodiments, 502 is a second functionallayer. In some embodiments, functional layer 502 is a second etch stoplayer similar to the first etch stop layer. For example, as shown inFIG. 6 , operation 601 may include forming functional layer 502 bydeposition of a second etch stop layer (ESL2). In some embodiments,functional layer 502 comprises or is silicon nitride, silicon carbonnitride, silicon carbon oxide, carbon nitride, silicon carbide, thelike, or a combination thereof deposited by an appropriate depositionprocess on functional layer 501. In some embodiments, thickness offunctional layer 502 is in a range of about 300 Angstroms to 1000Angstroms. In some embodiments, functional layer 502 is formed of thesame material as functional layer 501. In some embodiments, functionallayer 502 is formed of silicon carbide and has thickness of about 750Angstroms. It may be advantageous to use a thick functional layer 502both to avoid forming voids in the functional layer 502 and to increasethickness of via 213 and oxide thickness t_(ox). An excessively thickfunctional layer 502 may increase etching time and volume of etchantconsumed to etch through functional layer 502.

FIG. 5 d shows an intermediate semiconductor structure after performingoperation 602 of FIG. 6 . In FIG. 5 d , dielectric layer 511 is formedon functional layer 502. In some embodiments, dielectric layer 511 is afirst dielectric layer. In some embodiments, dielectric layer 511 isformed of a dielectric material deposited, by an appropriate depositionprocess, on the functional layer 502. In some embodiments, thedielectric material may comprise or be silicon dioxide, a low-kdielectric material (e.g., a material having a dielectric constant lowerthan silicon dioxide), silicon oxynitride, phosphosilicate glass (PSG),borosilicate glass (BSG), borophosphosilicate glass (BPSG), undopedsilicate glass (USG), fluorinated silicate glass (FSG), organosilicateglasses (OSG), SiOxCy, Spin-On-Glass, Spin-On-Polymers, silicon carbonmaterial, a compound thereof, a composite thereof, the like, or acombination thereof. For example, as shown in FIG. 6 , operation 602 mayinclude forming dielectric layer 511 by deposition of a first oxidelayer (OX1). In some embodiments, thickness of dielectric layer 511 isin a range of about 4 kilo-Angstroms to about 30 kilo-Angstroms. In someembodiments, thickness of dielectric layer 511 is in a range of about 20kilo-Angstroms to about 30 kilo-Angstroms. In some embodiments,dielectric layer 511 is formed of USG and has a thickness of about 25kilo-Angstroms. A thicker dielectric layer 511 is advantageous toincrease thickness of via 213 and oxide thickness t_(ox). An excessivelythick dielectric layer 511 will consume more time and material inproduction and may also adversely impact process uniformity.

FIG. 5 e shows an intermediate semiconductor structure after performingoperation 603 of FIG. 6 . In FIG. 5 e , functional layer 503 is formedon dielectric layer 511. In some embodiments, functional layer 503 is athird functional layer. In some embodiments, functional layer 503 is athird etch stop layer. For example, as shown in FIG. 6 , operation 603may include forming functional layer 503 by deposition of a third etchstop layer (ESL3). In some embodiments, functional layer 503 is formedof a dielectric material. In some embodiments, functional layer 503comprises or is silicon nitride, silicon carbon nitride, silicon carbonoxide, carbon nitride, silicon carbide, the like, or a combinationthereof deposited by an appropriate deposition process on dielectriclayer 511. In some embodiments, thickness of functional layer 503 is ina range of about 200 Angstroms to 1000 Angstroms. In some embodiments,functional layer 503 is formed of a different material as the first andsecond etch stop layers. In some embodiments, functional layer 503 isformed of silicon nitride and has thickness of about 500 Angstroms. Itmay be advantageous to use a thick functional layer 503 both to avoidforming voids in the functional layer 503 and to increase thickness ofvia 213 and oxide thickness t_(ox). An excessively thick functionallayer 503 may increase etching time and volume of etchant consumed toetch through functional layer 503.

FIG. 5 f shows an intermediate semiconductor structure after performingoperation 604 of FIG. 6 . In FIG. 5 f , dielectric layer 512 is formedon functional layer 503. In some embodiments, dielectric layer 512 is asecond dielectric layer. In some embodiments, dielectric layer 512 isdeposited, by an appropriate deposition process, on functional layer503. In some embodiments, dielectric layer 512 is formed of a dielectricmaterial. In some embodiments, dielectric layer 512 comprises or issilicon dioxide, a low-k dielectric material, silicon oxynitride, PSG,BSG, BPSG, USG, FSG, OSG, SiOxCy, Spin-On-Glass, Spin-On-Polymers,silicon carbon material, a compound thereof, a composite thereof, thelike, or a combination thereof. For example, as shown in FIG. 6 ,operation 604 may include forming dielectric layer 512 by deposition ofa second oxide layer (OX2). In some embodiments, thickness of dielectriclayer 512 is in a range of about 4 kilo-Angstroms to about 30kilo-Angstroms. In some embodiments, thickness of dielectric layer 512is greater than about 5 kilo-Angstroms, greater than about 10kilo-Angstroms, greater than about 20 kilo-Angstroms or greater thanabout 30 kilo-Angstroms. In some embodiments, the dielectric layer 512is formed of a same material as the dielectric layer 511. In someembodiments, the dielectric layer 512 is formed of USG and has athickness of about 26 kilo-Angstroms. In some embodiments, dielectriclayer 512 is formed of USG and has a thickness of about 25kilo-Angstroms. A thicker dielectric layer 512 is advantageous toincrease thickness of via 213 and oxide thickness t_(ox). An excessivelythick dielectric layer 512 will consume more time and material inproduction and may also adversely impact process uniformity. Thecombination of dielectric layers 511, 512 and functional layer 503allows for greater thickness of via 213, while splitting etching of thedielectric layers 511, 512 into two separate operations, which mayimprove uniformity and yield.

FIG. 5 g shows an intermediate semiconductor structure after performingoperation 605 of FIG. 6 . In FIG. 5 g , functional layer 504 is formedon dielectric layer 512. In some embodiments, functional layer 504 is afourth functional layer. In some embodiments, functional layer 504 is afirst anti-reflective layer. For example, as shown in FIG. 6 , operation605 may include forming functional layer 503 by deposition of a firstanti-reflective layer (AR1). The first anti-reflective layer is used tomitigate reflections from underlying layers which are reflective tolight used in a subsequent lithographic process. In some embodiments,functional layer 504 comprises or is silicon oxide, silicon oxycarbide,silicon oxynitride, hydrocarbon-containing silicon oxide, siliconnitride, titanium nitride, tantalum nitride, titanium containingmaterial, tantalum containing material, an organic material, or anycombination thereof. In some embodiments, functional layer 504 comprisesor is a nitrogen-free material, such as a nitrogen-free oxide. In someembodiments, functional layer 504 comprises or is a nitrogen-freesilicon oxycarbide. Functional layer 504 is deposited on dielectriclayer 512 by any suitable technique, such as CVD, plasma-enhanced CVD(PECVD), high-density plasma CVD (HDP-CVD), spin-on coating process, orthe like. In some embodiments, thickness of functional layer 504 is in arange of about 300 Angstroms to 1000 Angstroms. In some embodiments,functional layer 504 is formed of silicon oxynitride and has a thicknessof about 600 Angstroms. Thickness of the functional layer 504 may bechosen to be thick enough to prevent voids to provide a uniformanti-reflective function, while also being thin enough to account formaterial and deposition cost of the layer, as well as etchant materialand time cost for etching the layer, and slurry material and time costfor planarizing/removing the layer.

FIG. 5 h shows an intermediate semiconductor structure formed afterperforming operation 606 of FIG. 6 . At operation 606, opening 541 isformed. Opening 541 is formed through functional layer 504, dielectriclayer 512, functional layer 503, dielectric layer 511, functional layer502 and functional layer 501. Opening 541 can be formed using apatterned photoresist layer that defines an opening pattern followed bya suitable etching process. For example, as shown in FIG. 6 , operation606 may include forming opening 541 by at least one first lithographyoperation and at least one first etch operation (Litho+Etch 1). Thepatterned photoresist layer is then removed using any suitable strippingprocess. Opening 541 exposes a portion of the top surface of secondmetal line 212 to provide an electrical connection.

FIG. 5 i shows an intermediate semiconductor structure after performingoperation 607 of FIG. 6 . In FIG. 5 i , conductive plug 531 is formed inopening 541, and on functional layer 504. For example, as shown in FIG.6 , operation 607 may include forming conductive plug 531 by a firstelectroless copper plating process (ECP 1). Conductive plug 531substantially fills the removed portions of functional layer 504,dielectric layer 512, functional layer 503, dielectric layer 511,functional layer 502 and functional layer 501 which comprise opening541, and directly contacts second metal line 212. In some embodiments,conductive plug 531 is formed of at least one conductive material. Insome embodiments, the at least one conductive material is or comprises ametal, such as tungsten, copper, aluminum, gold, silver, alloys thereof,the like, or a combination thereof, and may be deposited by chemicalvapor deposition (CVD), atomic layer deposition (ALD), physical vapordeposition (PVD), electroplating, electroless plating, or other suitablemethod. In some embodiments, conductive plug 531 is formed using a dualdamascene process. In some embodiments, the plating process is anelectroless copper plating (ECP) process. In some embodiments, theelectroless copper plating process is preceded by forming a seed layeron sidewalls of the removed portions. In some embodiments, the seedlayer is a barrier seed layer.

FIG. 5 j shows an intermediate semiconductor structure after performingoperation 608 of FIG. 6 . In FIG. 5 j , conductive plug 531 isplanarized and/or polished to form first metal line 211. For example, asshown in FIG. 6 , operation 608 may include polishing and/or planarizingconductive plug 531 by a first chemical mechanical polishing process(CMP 1). In some embodiments, after conductive plug 531 is formed andfilled in the opening 541, a chemical mechanical polishing (CMP)operation removes any excess material of conductive plug 531, and anyremaining mask, such as functional layer 504 to have a top surface ofconductive plug 531 substantially coplanar with a top surface ofdielectric layer 512, as shown in FIG. 5 j . In some embodiments,thickness of dielectric layer 512 is reduced after performing operation608 by about 20%. The thickness of the dielectric layer 512 may bereduced by less than about 20% if sufficient planarity may be achievedwhile polishing away less material of the dielectric layer 512.

FIG. 5 k shows an intermediate semiconductor structure after performingoperation 609, operation 610, operation 611 and operation 612 of FIG. 6. Operation 609 includes forming functional layer 505. In someembodiments, functional layer 505 is a fifth functional layer. In someembodiments, functional layer 505 is an etch stop layer. For example, asshown in FIG. 6 , operation 609 may include forming functional layer 505by deposition of a fourth etch stop layer (ESL4). In some embodiments,functional layer 505 is formed of a dielectric material. In someembodiments, functional layer 505 comprises or is silicon nitride,silicon carbon nitride, silicon carbon oxide, carbon nitride, siliconcarbide, the like, or a combination thereof deposited by an appropriatedeposition process on functional layer 512 and conductive via 213. Insome embodiments, thickness of functional layer 505 is in a range ofabout 200 Angstroms to 1000 Angstroms. In some embodiments, functionallayer 505 is formed of a different material as the first and second etchstop layers. In some embodiments, functional layer 505 is formed ofsilicon nitride and has thickness of about 500 Angstroms. It may beadvantageous to use a thick functional layer 505 both to avoid formingvoids in the functional layer 505. An excessively thick functional layer505 may increase etching time and volume of etchant consumed to etchthrough functional layer 505.

Operation 610 of the flowchart 60 of FIG. 6 includes forming functionallayer 506. In some embodiments, functional layer 506 is a sixthfunctional layer. In some embodiments, functional layer 506 is ananti-reflective layer deposited on functional layer 505. For example, asshown in FIG. 6 , operation 610 may include forming functional layer 506by deposition of a second anti-reflective layer (AR2). In someembodiments, functional layer 506 is formed of a dielectric material. Insome embodiments, functional layer 506 comprises or is silicon oxide,silicon oxycarbide, silicon oxynitride, hydrocarbon-containing siliconoxide, silicon nitride, titanium nitride, tantalum nitride, titaniumcontaining material, tantalum containing material, an organic material,or any combination thereof. In some embodiments, functional layer 506comprises or is a nitrogen-free material, such as a nitrogen-free oxide.In some embodiments, functional layer 506 comprises or is anitrogen-free silicon oxycarbide. Functional layer 506 is deposited onfunctional layer 505 by any suitable technique, such as CVD,plasma-enhanced CVD (PECVD), high-density plasma CVD (HDP-CVD), spin-oncoating process, or the like. In some embodiments, thickness offunctional layer 506 is in a range of about 200 Angstroms to 1000Angstroms. In some embodiments, functional layer 506 is formed ofsilicon oxynitride, and has thickness of about 600 Angstroms. Thicknessof the functional layer 506 may be chosen to be thick enough to preventvoids to provide a uniform anti-reflective function, while also beingthin enough to account for material and deposition cost of the layer, aswell as etchant material and time cost for etching the layer, and slurrymaterial and time cost for planarizing/removing the layer.

Operation 611 includes forming dielectric layer 513. In someembodiments, dielectric layer 513 is a third dielectric layer depositedon functional layer 506. In some embodiments, dielectric layer 513comprises or is silicon dioxide, a low-k dielectric material, siliconoxynitride, PSG, BSG, BPSG, USG, FSG, OSG, SiOxCy, Spin-On-Glass,Spin-On-Polymers, silicon carbon material, a compound thereof, acomposite thereof, the like, or a combination thereof. For example, asshown in FIG. 6 , operation 611 may include forming dielectric layer 513by deposition of a third oxide layer (OX3). In some embodiments,thickness of dielectric layer 513 is in a range of about 4kilo-Angstroms to about 30 kilo-Angstroms. In some embodiments,thickness of dielectric layer 513 is greater than about 5kilo-Angstroms, greater than about 10 kilo-Angstroms, greater than about20 kilo-Angstroms, greater than about 30 kilo-Angstroms or greater thanabout 40 kilo-Angstroms. In some embodiments, dielectric layer 513 isformed of USG, and has thickness of about 38 kilo-Angstroms. Thicknessof dielectric layer 513 may be similar to or slightly greater thandesired thickness of the top metal layer. Excessive thickness ofdielectric layer 513 will increase planarization time and consumedmaterials, e.g. slurry, to achieve the desired thickness of the topmetal layer. An excessively thick top metal layer may cause unwantedstress that may lead to delamination in the intermediate or bottom metallayer/layers.

Operation 612 includes forming functional layer 507. In someembodiments, functional layer 507 is a seventh functional layerdeposited on dielectric layer 513. In some embodiments, functional layer507 is an anti-reflective layer. For example, as shown in FIG. 6 ,operation 612 may include forming functional layer 507 by deposition ofa third anti-reflective layer (AR3). In some embodiments, functionallayer 507 comprises or is silicon oxide, silicon oxycarbide, siliconoxynitride, hydrocarbon-containing silicon oxide, silicon nitride,titanium nitride, tantalum nitride, titanium containing material,tantalum containing material, an organic material, or any combinationthereof. In some embodiments, functional layer 507 comprises or is anitrogen-free material, such as a nitrogen-free oxide. In someembodiments, functional layer 507 comprises or is a nitrogen-freesilicon oxycarbide. Functional layer 507 is deposited on functionallayer 507 by any suitable technique, such as CVD, plasma-enhanced CVD(PECVD), high-density plasma CVD (HDP-CVD), spin-on coating process, orthe like. In some embodiments, thickness of functional layer 507 is in arange of about 200 Angstroms to 1000 Angstroms. Thickness of thefunctional layer 507 may be chosen to be thick enough to prevent voidsto provide a uniform anti-reflective function, while also being thinenough to account for material and deposition cost of the layer, as wellas etchant material and time cost for etching the layer, and slurrymaterial and time cost for planarizing/removing the layer.

FIG. 5 l shows an intermediate semiconductor structure after performingoperation 613 of FIG. 6 . At operation 613, opening 542 is formed.Opening 542 is formed through functional layer 507, dielectric layer513, functional layer 506, and functional layer 505. Opening 542 can beformed using a patterned photoresist layer that defines an openingpattern followed by a suitable etching process. For example, as shown inFIG. 6 , operation 613 may include forming opening 542 by at least onesecond lithography operation and at least one second etch operation(Litho+Etch 2). The patterned photoresist layer is then removed usingany suitable stripping process. Opening 542 exposes a portion of the topsurface of conductive via 213 to provide an electrical connection.

FIG. 5 m shows an intermediate semiconductor structure after performingoperation 614 of FIG. 6 . In FIG. 5 m , conductive plug 532 is formed inopening 542, and on functional layer 507. For example, as shown in FIG.6 , operation 614 may include forming conductive plug 532 by a secondelectroless copper plating process (ECP 2). Conductive plug 532substantially fills the removed portions of functional layer 507,dielectric layer 513, functional layer 506 and functional layer 505which comprise opening 542, and directly contacts conductive via 213. Insome embodiments, conductive plug 532 is formed of at least oneconductive material. In some embodiments, the at least one conductivematerial is or comprises a metal, such as tungsten, copper, aluminum,gold, silver, alloys thereof, the like, or a combination thereof, andmay be deposited by chemical vapor deposition (CVD), atomic layerdeposition (ALD), physical vapor deposition (PVD), electroplating,electroless plating, or other suitable method. In some embodiments,conductive plug 532 is formed using a dual damascene process. In someembodiments, the plating process is an electroless copper plating (ECP)process. In some embodiments, the electroless copper plating process ispreceded by forming a seed layer on sidewalls of the removed portions.In some embodiments, the seed layer is a barrier seed layer.

FIG. 5 n shows structure 210 after performing operation 615 of FIG. 6 .In FIG. 5 n , conductive plug 532 is planarized and/or polished to formfirst metal line 211. For example, as shown in FIG. 6 , operation 615may include polishing and/or planarizing conductive plug 532 by a secondchemical mechanical polishing process (CMP 2). In some embodiments,after conductive plug 532 is formed and filled in opening 542, achemical mechanical polish (CMP) removes any excess material ofconductive plug 532, and any remaining mask, such as functional layer507 to have a top surface of conductive plug 532 substantially coplanarwith a top surface of dielectric layer 513, as shown in FIG. 5 n . Insome embodiments, thickness of dielectric layer 513 is reduced afterperforming operation 615.

FIG. 6 is explained above with reference to FIG. 5 a to FIG. 5 n . Insome embodiments, the flowchart 60 includes more or fewer processes thandepicted in FIG. 6 . In some embodiments, forming functional layer 502,which corresponds to operation 601 is omitted. In some embodiments,operation 614 includes at least two electroless copper platingoperations. In some embodiments, a baking operation is performed afteroperation 613 and prior to operation 614 and/or after operation 614 andprior to operation 615. Other embodiments may include further functionallayer deposition operations and/or baking.

FIG. 7 is a circuit block diagram of passive radio frequency device 70in accordance with some embodiments. In some embodiments, the passiveradio frequency device 70 is a radio frequency identification (RFID)transceiver of an RFID tag. Any RFID tag having no internal power supplyis considered “passive.” Passive RFID tags harvest power from receivedradio frequency signals, typically from an RFID reader device, and reusethe harvested power to transmit a response to the RFID reader device.

The passive radio frequency device 70 may include terminal 720 forreceiving radio frequency signals. In some embodiments, terminal 720 iselectrically connected to or otherwise includes an antenna.

Terminal 730 of passive radio frequency device 70 is an output terminalfor emitting radio frequency signals. In some embodiments, terminal 730includes an antenna. In some embodiments, terminal 730 and terminal 720include the same antenna.

Circuitry 700 of passive radio frequency device 70 is electricallyconnected to terminal 720 and terminal 730. In some embodiments,circuitry 700 includes one or more of a modulator, a demodulator, powerrecovery/harvesting circuitry, a clock, control circuitry, processingcircuitry, coding circuitry, decoding circuitry, or memory.

Passive radio frequency device 70 includes inductor circuit 10. In someembodiments, inductor circuit 10 is used to receive the radio frequencysignals. Inductor circuit 10 is electrically connected to circuitry 700.Inductor circuit 10 includes at least via 213 in dielectric layer 513,and first metal line 211 substantially directly contacting via 213 andextended through dielectric layer 511, dielectric layer 512, andfunctional layer 503. Inductor circuit 10 has enhanced quality factordue to reduced C_(ox) by increased upper conductive via thickness, asdescribed above with respect to at least FIG. 3 . Passive radiofrequency device 70 including inductor circuit 10 has improvedsensitivity when receiving the radio frequency signals, and alsoimproved ability to reject unwanted radio frequency signals.

FIG. 8 is a circuit block diagram of active radio frequency device 80 inaccordance with some embodiments. In some embodiments, active radiofrequency device 80 is a radio frequency identification (RFID)transceiver of an RFID tag. Any RFID tag having an internal power supplyis considered “active.” Active RFID tags generally do not need toharvest power from received radio frequency signals, typically from anRFID reader device, and use power from the internal power supply totransmit a response to the RFID reader device. As such, while activeradio frequency device 80 may include many similar electronic componentsto passive radio frequency device 70, configuration of the electroniccomponents in active radio frequency device 80 may differ significantlyfrom the configuration in passive radio frequency device 70. As such,different reference numerals are used throughout FIG. 8 .

Terminal 820 of active radio frequency device 80 is an input terminalfor receiving radio frequency signals. In some embodiments, terminal 820includes an antenna.

Terminal 830 of active radio frequency device 80 is an output terminalfor emitting radio frequency signals. In some embodiments, terminal 830includes an antenna. In some embodiments, terminal 830 and terminal 820include the same antenna.

Circuitry 800 of active radio frequency device 80 is electricallyconnected to terminal 820 and terminal 830. In some embodiments,circuitry 800 includes one or more of a modulator, a demodulator, aclock, control circuitry, processing circuitry, coding circuitry,decoding circuitry, or memory.

Power source 810 of active radio frequency device 80 is electricallyconnected to circuitry 800. Power source 810 provides power to circuitry800. In some embodiments, power source 810 includes at least a battery.In some embodiments, power source 810 includes power managementcircuitry.

Active radio frequency device 80 includes inductor circuit 10. In someembodiments, inductor circuit 10 is used to receive the radio frequencysignals. Inductor circuit 10 is electrically connected to circuitry 800.Inductor circuit 10 includes at least via 213 in dielectric layer 513,and first metal line 211 substantially directly contacting via 213 andextended through dielectric layer 511, dielectric layer 512, andfunctional layer 503. Inductor circuit 10 has enhanced quality factordue to reduced C_(ox), by increased upper conductive via thickness, asdescribed above with respect to at least FIG. 3 . Active radio frequencydevice 80 including inductor circuit 10 has improved sensitivity whenreceiving the radio frequency signals, and also improved ability toreject unwanted radio frequency signals.

FIG. 9 is a circuit block diagram of voltage controlled oscillatordevice 90 in accordance with some embodiments. Voltage controlledoscillator device 90 outputs a first clock at terminal 920 and a secondclock at terminal 930 substantially the inverse of the first clock, bothat a frequency controlled by a control voltage at terminal 970. Voltagecontrolled oscillator device 90 of FIG. 9 illustrates a voltagecontrolled oscillator including inductor circuit 10. In someembodiments, inductor circuit 10 is utilized as an on-chip inductor in avoltage controlled oscillator device utilizing a different architecturethan that shown in FIG. 9 .

Inverter 900 of voltage controlled oscillator device 90 outputs a firstoutput signal at terminal 930 that is substantially the inverse of thefirst clock at terminal 920. An input terminal of inverter 900 forreceiving the first clock is electrically connected to an outputterminal of inverter 910, a first terminal of inductor circuit 10, afirst terminal of capacitor 940, and a first terminal of variablecapacitor 950. An output terminal of inverter 900 for outputting thesecond clock is electrically connected to an input terminal of inverter910, a second terminal of inductor circuit 10, a second terminal ofcapacitor 940, and a first terminal of variable capacitor 960.

Inverter 910 of voltage controlled oscillator device 90 outputs thefirst clock at terminal 920 that is substantially the inverse of thesecond clock at terminal 930. An input terminal of inverter 910 forreceiving the second clock is electrically connected to an outputterminal of inverter 900, the second terminal of inductor circuit 10,the second terminal of capacitor 940, and the first terminal of variablecapacitor 960. An output terminal of inverter 910 for outputting thefirst clock is electrically connected to the input terminal of inverter900, the first terminal of inductor circuit 10, the first terminal ofcapacitor 940, and the first terminal of variable capacitor 950.

Inductor circuit 10, capacitor 940, variable capacitor 950 and variablecapacitor 960 form a variable LC tank circuit that is tuned by thecontrol voltage at terminal 970. The first terminal of inductor circuit10 is electrically connected to the input terminal of inverter 900, theoutput terminal of inverter 910, the first terminal of capacitor 940,and the first terminal of variable capacitor 950. The second terminal ofinductor circuit 10 is electrically connected to the output terminal ofinverter 900, the input terminal of inverter 910, the second terminal ofcapacitor 940, and the first terminal of variable capacitor 960.

Inductor circuit 10 includes at least via 213 in dielectric layer 513,and first metal line 211 substantially directly contacting via 213 andextended through dielectric layer 511, dielectric layer 512, andfunctional layer 503. Inductor circuit 10 has enhanced quality factordue to reduced C_(ox) by increased upper conductive via thickness, asdescribed above with respect to at least FIG. 3 . Voltage controlledoscillator device 90 has improved phase noise due to the enhancedquality factor.

Capacitor 940 of the LC tank circuit is a fixed capacitor. In someembodiments, capacitor 940 is a metal-oxide-metal (MOM) capacitor, ametal-insulator-metal (MIM) capacitor, or the like. The first terminalof capacitor 940 is electrically connected to the input terminal ofinverter 900, the first terminal of inductor circuit 10, the firstterminal of variable capacitor 950, and the output terminal of inverter910. The second terminal of capacitor 940 is electrically connected tothe output terminal of inverter 900, the second terminal of inductorcircuit 10, the first terminal of variable capacitor 960 and the inputterminal of inverter 910.

Variable capacitor 950 of the LC tank circuit is a variable capacitor.In some embodiments, variable capacitor 950 is ametal-oxide-semiconductor (MOS) capacitor. The first terminal ofvariable capacitor 950 is electrically connected to the input terminalof inverter 900, the first terminal of inductor circuit 10, the firstterminal of capacitor 940, and the output terminal of inverter 910. Asecond terminal of variable capacitor 950 is electrically connected to asecond terminal of variable capacitor 960 and terminal 970.

Variable capacitor 960 of the LC tank circuit is a variable capacitor.In some embodiments, variable capacitor 960 is ametal-oxide-semiconductor (MOS) capacitor. The first terminal ofvariable capacitor 960 is electrically connected to the output terminalof inverter 900, the second terminal of inductor circuit 10, the secondterminal of capacitor 940, and the input terminal of inverter 910. Thesecond terminal of variable capacitor 960 is electrically connected tothe second terminal of variable capacitor 950 and terminal 970.

In addition, an integrated circuit device may include active deviceslocated in or on the substrate 240 and interconnects directly orindirectly coupling at least one of the active device or the inductor100. A complementary metal-oxide-semiconductor (CMOS) device, and otheractive and/or passive devices may be included in an integrated circuitdevice and/or coupled directly or indirectly to the inductor 100. Theinductor 100 may be advantageous in high frequency applications of theintegrated circuit device. Moreover, implementation of the inductor 100into existing fabrication processes may be simple and cost effective.For example, fabrication of the inductor 100 may be achieved byemploying existing fabrication techniques as future-developed techniquesmay also be employed. In addition, one or more of the via 213 or thefirst metal line 211 may be formed simultaneously with other existingmetallization layers, such that incorporation of the inductor 100 intoexisting designs may not require additional process steps.

Various embodiments of integrated circuit structures and process flowsdirected toward increasing oxide thickness t_(ox) with a view toreducing substrate loss factor and self-resonance factor to increasequality factor of on-chip inductors are described. Further embodimentsof devices, including both passive and active radio frequencyidentification (RFID) transceivers and a voltage controlled oscillator(VCO), are also described. To enhance inductor quality factor andoverall device performance, in some embodiments, oxide thickness t_(ox)is increased by extending an upper conductive via through at least twodielectric layers. In some embodiments, the oxide thickness is furtherincreased by extending the upper conductive via through at least oneetch stop layer positioned between the at least two dielectric layers. Qfactor for a 0.5 nano-Henry on-chip inductor is greater than about 22when using the structures and processes described herein. Sensitivity ofthe RFID transceivers or phase noise of the VCO is improved due to theexcellent quality factor of the inductor.

An embodiment of a device comprises a substrate, a first conductivelayer, a first conductive via, a plurality of second conductive layer,and a plurality of second conductive vias. The first conductive layer ison the substrate. The first conductive via is between the firstconductive layer and the substrate, and is electrically connected to thefirst conductive layer. The first conductive via has thickness greaterthan about 8 kilo-Angstroms. The plurality of second conductive layersis between the first conductive via and the substrate. The plurality ofsecond conductive vias is between the first conductive via and thesubstrate.

An embodiment of a method includes forming a first dielectric layer on afirst conductive layer. A second dielectric layer is formed on the firstdielectric layer. A conductive via extending through the firstdielectric layer and the second dielectric layer is formed. A thirddielectric layer is formed on the second dielectric layer. At least afirst conductive portion of an inductor is formed in the thirddielectric layer and in direct contact with the conductive via.

Another embodiment of a device includes a first dielectric layer, asecond dielectric layer, a first etch stop layer, a third dielectriclayer, and an inductor. The second dielectric layer is on the firstdielectric layer. The first etch stop layer is between the firstdielectric layer and the second dielectric layer. The third dielectriclayer is on the second dielectric layer. The inductor includes aconductive trace in the third dielectric layer, and a conductive viasubstantially directly contacting the conductive trace and extendedthrough the first dielectric layer, the second dielectric layer, and thefirst etch stop layer. Circuitry is electrically coupled to theinductor.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A device, comprising: a substrate; a firstconductive layer on the substrate; a second conductive layer between thefirst conductive layer and the substrate; a first conductive via incontact with the first conductive layer and the second conductive layer;a plurality of third conductive layers between the second conductivelayer and the substrate; and a dielectric layer between the firstconductive layer and the second conductive layer, the first conductivevia extending completely through the dielectric layer, the dielectriclayer including: a first functional layer on and in contact with thesecond conductive layer, the first functional layer being a differentmaterial than the second conductive layer; a second functional layer onand in contact with the first functional layer; a first oxide layer onand in contact with the second functional layer, the first oxide layerbeing a different material than the second functional layer; an etchstop layer on and in contact with the first oxide layer, the etch stoplayer being a different material than the first oxide layer; and asecond oxide layer on the etch stop layer, the second oxide layer beingin contact with the etch stop layer and the first conductive layer, thesecond oxide layer being a different material than the etch stop layer.2. The device of claim 1, further comprising an inductor at leastpartially disposed in the first conductive layer and including the firstconductive via.
 3. The device of claim 1, further comprising a seconddielectric layer on the dielectric layer, the first conductive layerbeing positioned in the second dielectric layer.
 4. The device of claim3, further comprising an anti-reflective layer between the seconddielectric layer and the second oxide layer.
 5. The device of claim 4,further comprising a second etch stop layer between the anti-reflectivelayer and the second oxide layer.
 6. The device of claim 1, wherein thefirst conductive via has thickness in a range of about 16 kilo-Angstromsto about 60 kilo-Angstroms.
 7. A device, comprising: a first etch stoplayer; a second etch stop layer on and in contact with the first etchstop layer; a first dielectric layer on and in contact with the secondetch stop layer, the first dielectric layer being a different materialthan the second etch stop layer; a second dielectric layer on the firstdielectric layer; a third etch stop layer between the first dielectriclayer and the second dielectric layer, the third etch stop layer havinga first surface in contact with the first dielectric layer, and having asecond surface in contact with the second dielectric layer, the firstsurface facing in a direction opposite that of the second surface, thethird etch stop layer being a different material than the firstdielectric layer and the second dielectric layer; a third dielectriclayer on the second dielectric layer; a first conductive trace in thethird dielectric layer; a conductive via substantially directlycontacting the first conductive trace and extended completely throughthe first etch stop layer, the second etch stop layer, the firstdielectric layer, the second dielectric layer, and the third etch stoplayer; and a second conductive trace in contact with the conductive via,the second conductive trace being on a side of the conductive viaopposite that of the first conductive trace.
 8. The device of claim 7,further comprising an inductor including the first conductive trace. 9.The device of claim 7, further comprising an anti-reflective layerbetween the third dielectric layer and the second dielectric layer. 10.The device of claim 9, further comprising a second etch stop layerbetween the anti-reflective layer and the second dielectric layer. 11.The device of claim 7, wherein the first conductive via has thickness ina range of about 16 kilo-Angstroms to about 60 kilo-Angstroms.
 12. Thedevice of claim 7, wherein the first dielectric layer has thickness in arange of about 20 kilo-Angstroms to about 30 kilo-Angstroms, and thesecond dielectric layer has thickness in a range of about 20kilo-Angstroms to about 30 kilo-Angstroms.
 13. The device of claim 12,further comprising: a third conductive layer between the secondconductive trace and the substrate, the third conductive layer havingthickness less than about 7 kilo-Angstroms.
 14. A device, comprising: aninductor over a substrate, the inductor including: a first tracevertically separated from the substrate by a plurality of third traces;a second trace over the first trace; and a via contacting the firsttrace and the second trace, the via extending completely through adielectric layer, the dielectric layer including: a first functionallayer on and in contact with the first trace, the first functional layerbeing a different material than the first trace; a second functionallayer on and in contact with the first functional layer; a firstdielectric layer on and in contact with the second functional layer, thefirst dielectric layer being a different material than the secondfunctional layer; an etch stop layer on and in contact with the firstdielectric layer, the etch stop layer being a different material thanthe first dielectric layer; and a second dielectric layer on the etchstop layer, the second dielectric layer being in contact with the etchstop layer and the second trace, the second dielectric layer being adifferent material than the etch stop layer; an antenna, wherein theantenna, in operation, receives radio frequency signals; and circuitryelectrically connected to the inductor and the antenna.
 15. The deviceof claim 14, further comprising a third dielectric layer on thedielectric layer, the first trace being positioned in the thirddielectric layer.
 16. The device of claim 15, further comprising ananti-reflective layer between the third dielectric layer and the seconddielectric layer.
 17. The device of claim 16, further comprising asecond etch stop layer between the anti-reflective layer and the seconddielectric layer.
 18. The device of claim 14, wherein the via hasthickness in a range of about 16 kilo-Angstroms to about 60kilo-Angstroms.
 19. The device of claim 18, wherein each of theplurality of third traces has thickness less than about 7kilo-Angstroms.
 20. The device of claim 14, wherein the first and seconddielectric layers are oxide layers.